Edge-sealing system &amp; method

ABSTRACT

A polymer board with a cut edge is automatically advanced through a stationary, non-spinning sealing element that contacts and compresses the cut edge and provides a sealed and smooth surface to the cut edge.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority of U.S. provisionalapplication No. 62/220,281, filed Sep. 18, 2015, which is incorporatedherein by reference.

BACKGROUND

Many of the cellular polyvinyl chloride (PVC) trim board manufacturershave used heated, rolling wheels to seal the edge of their trim boards,such as disclosed by U.S. Pat. No. 8,333,582 and published applicationUS 2013/0099416 (both incorporated herein by reference). While suchearlier process was an improvement from the un-sealed, open cellstructure from the prior vintage of trim boards, the sealed edges fromthis process did not fully seal the surface, and did not provide an edgethat was materially similar to the extruded top and bottom surface ofthe trim boards. The standard test to estimate how well the edge wassealed was “the pencil test”. This included drawing a line with agraphite lead pencil and then attempting to erase the line with thepencil's eraser. Any open cell structure would capture graphite in thecells which could not be removed with the eraser and indicate that thesurface was not fully sealed.

SUMMARY

To answer the deficiencies of prior sealing systems and methods, thepresent invention creates a sealed surface where all visible traces ofgraphite can be erased away. In addition, a more precise test ofmeasuring the gloss level of the sealed edge versus the top and bottomof the trim board demonstrates that the sealed edge with this newtechnology more accurately approximates the extruded surface of the topand bottom of the trim board.

The present invention includes a system and method of sealing open cellstructure resulting from cutting foamed polymer sheets into individualboards. Embodiments of the invention include multiple stationary sealingelements that can be operated from ambient temperature to elevatedtemperatures (wherein one or more pairs may apply heat). The edges ofthe board are routed or milled to ensure a flat, squared surface. Theedges are then passed between stationary elements that apply pressure,creating friction as the board slides along the sealing elements. Someor all of the elements may be heated to cause softening, or melting ofthe outer most layer of material. Subsequent elements may operate atlower temperatures and higher pressures that freeze and cold work theouter layer of material. The resulting surface is a sealed, slightlytextured surface similar to the uncut, extruded top and bottom surfaceof the board.

In embodiments of the invention, extruded PVC boards that have been cutalong their length (and therefore have rough side edges) have the sidessealed by pulling the boards through a system that applies hot pressurefrom stationary bars abutting the rough sides of each PVC board.Specifically, most PVC trim board is manufactured by extruding 48″ widefoamed PVC sheets which are then ripped (cut) into traditional wood trimwidths, i.e., 1×4, 1×6, 1×8, etc. Where the boards are cut, the cutsurface results in an exposed open cell surface, whereas the top andbottom surface which is not cut has a nice, smooth extruded skin. Mosttrim board manufacturers have now implemented “edge sealing” to somewhatmelt and seal the cut edges to eliminate, or reduce the exposure of theopen cell surface. For example, U.S. Pat. No. 8,333,582 and pendingapplication published as US 2013/0099416 disclose using heated, rotatingand motor-driven rollers to transport the material through the machineand melt and create a skin on the exposed surface.

By contrast, embodiments of the present invention include a system wherethe cut PVC boards are (1) pulled with a pulling machine (on unheatedguide rollers) through stationary metal elements (ambient or heated) andfriction, pressure and heat create a skin on the rough, exposed surfaceand (2) further pulled through a stationary spool (or other cornershaping element) that, while the new skin on the sides is still hot,presses the corners of the sides of the board into a desirable roundedcorner shape (since it was found that simply creating the skin with hotelements led to the excess hot PVC moving to the corners and creatingundesirable sharp corners).

BRIEF DESCRIPTION OF THE DRAWINGS

In order to facilitate a fuller understanding of the exemplaryembodiments, reference is now made to the appended drawings. Thesedrawings should not be construed as limiting, but are intended to beexemplary only.

FIG. 1 illustrates a perspective view of a board with stationary sidesealing units applying heat and a puller roller pulling the board,according to one embodiment of the invention.

FIG. 2 illustrates a perspective view of a board with multiple pairs ofstationary side sealing units and multiple puller rollers pulling theboard, according to one embodiment of the invention.

FIG. 3 illustrates a perspective view of a pair of angled corner shapingunits pushing the warm corners of a board being pulled by puller rollerafter the board's exit from between a pair of stationary side sealingunits in one embodiment of the invention.

FIG. 4 illustrates a perspective view of two pairs of angled cornershaping units pushing the warm corners of a board being pulled by pullerroller after the board's exit from between a pair of stationary sidesealing units in one embodiment of the invention.

FIG. 5 illustrates a spool-shaped corner shaping unit as an alternativeto angled rod units as shown in FIGS. 3 and 4 in one embodiment of theinvention.

FIG. 6 illustrates a perspective view of a side edge sealing system withmultiple pairs of stationary side sealing units and multiple pullerrollers and also including a pair of corner shaping spools, according toone embodiment of the invention.

FIG. 7 illustrates a perspective view of a pair of sealing elementsconnected to dovetail guide blocks in one embodiment of the invention,

FIG. 8 illustrates a perspective view of sealing elements and dovetailguide blocks provided on each side of a machine in one embodiment of theinvention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The following description is intended to convey a thorough understandingof the embodiments by providing a number of specific embodiments anddetails involving a method and apparatus for manufacturing a decoratedextruded profile. It is understood, however, that the invention is notlimited to these specific embodiments and details, which are exemplaryonly. It is further understood that one possessing ordinary skill in theart, in light of known devices, systems and methods, would appreciatethe use of the invention for its intended purposes and benefits in anynumber of alternative embodiments.

Generally speaking, the various exemplary embodiments described hereinrelate to devices, systems and methods for sealing the edges ofcut/ripped cellular polyvinyl chloride (PVC) boards 50. It will beappreciated that embodiments of the invention may be applicable toboards that comprise other polymer and plastic materials beyond cellularPVC.

The resultant articles may be useful in, for example, deck systems,fence systems, building products, floor coverings, or componentsthereof, such as planks, slats, rails, posts, flooring, siding, roofingmaterials, and the like. In addition, the articles may have many of thedesirable properties of natural wood products, and may be sturdy,lightweight, and have excellent weatherability properties.

As shown in FIG. 1, the present invention seeks to answer the need ofextruded cellular PVC boards 50 that are cut and have rough edges forsuch edges (left and right side surfaces) 55 to be made smooth andapproximate the look and gloss of the extruded top and bottom surfaces.In embodiments, as shown in FIGS. 2 and 3, the PVC boards 50 are pulledby a pulling machine 130 and advanced in line through puller rollers 120for interaction with sealing head devices 100 having sealing units 105that preferably have a smooth, rounded and/or cylindrical shape. In someembodiments a system of the invention further includes corner shapingdevices 150 as shown in FIGS. 3-6.

In other embodiments it will be appreciated that push-machines,combinations of push and pull machines, conveyor systems and other boardadvancement techniques may be implemented to advance boards in anautomated production line. It is preferable that boards be advanced inembodiments of the present in invention in a range of 20 fpm (feet perminute) to 200 fpm, and more preferably from 60 fpm to 200 fpm.

In various embodiments, pairs of sealing units 105 positioned acrossfrom one another at opposite edges 55 of the board 50 may preferably beheated to achieve desired results. Such heating may preferably rangefrom about 115° F. to about 500° F. Different head devices 100 (whichprovide pairs of sealing units 105) may also be provided at differenttemperatures depending on variables such as the speed of advancement ofthe boards, the pressure (compression distance), desired results andother parameters. Preferably where a board 50 in the production line isfed above 60 fpm, such as tests conducted at 70 fpm, better edge sealingresulted where a first two pairs of sealing units were hotter (e.g.475-500° F.) than a last two pairs of sealing units (e.g 120-160° F.).It will be appreciated that in alternative embodiments, the rough boardedges 55 might be heated by blowers or other heating elements todesirable temperatures and then passed through unheated stationarysealing units 105 whereby compression is applied to achieve sealingwithout a sealing unit necessarily providing the heat to the edges 55.

In some embodiments of the invention it was determined that sealingunits 105 created sharp corners that could be viewed as undesirable invarious applications for a PVC board 50. To provide more rounded cornersto a board edge 55 sealed by the present invention, corner shapingelements 150 such as shown in FIGS. 3-6 are implemented. While suchshaping elements 150 are preferably not necessary to be heated as thecorner shaper 150 pushes the warm corners after leaving one or morepairs of heated sealing elements 105, in some embodiments the cornershapers 150 might be heated to provide a desired effect.

Referring to FIGS. 5 and 6, in one embodiment the corner shapers 150 maybe spool-shaped units 151 so that the curvature of the unit 151 providesdesirable interaction at the corners of sealed edges 55 of a board 50 ofthe invention. Preferably the spools 151 are free floating and are notheated, and can move up and down to “soften” the sharp corners. Thespools 151 are preferably stationary and do not spin, but apply drag orfriction between the surface of the spool 151 and the corner of theboard 50.

In alternative embodiments, such as shown in FIGS. 3 and 4, a cornershaping element 150 has a small, stationary metal bar/rod that is about45 degrees to each corner to eliminate a sharp edge from forming at thecorners of the board edges 55 during the sealing process. The cornershaping element 150 with angled bar provides similar corner shapingfunctions as the spool 151, but the angled bar/rod will contact thecorner of every thickness board (½″, ⅝″, ¾″ and 1″) at the same anglewhereas the radius of the spool 151 causes boards 50 of differentthicknesses to contact the spool 151 at different points and hence theangle of the contact surface for the spool 151 is not constant from onethickness to another.

In alternative embodiments of the invention shown in FIGS. 7 and 8, asturdier sealing system is utilized with the components of the inventionto provide improved performance of edge sealing, including good resultsat faster foot-per-minute run rates with less pressure between sealingelements. More sealing head elements 100 can also be provided in a morerigid machine. Specifically the size of the machine frame, and themechanisms holding the sealing units 105 were made physically larger,and with thicker metal, so there is much less bending or flexing of thestructure of the machine. It was found that the more rigid machine andthe additional sealing head elements 100 allowed using less pressure andrun at higher rates and achieve good quality sealed edges 55 that wereonly achieved with lower run rates on an alternative and less sturdydevelopment machine. With the more rigid machine and five pairs ofsealing head elements 100, the following conditions in “Table A,” withthe pairs of sealing elements numbered in order encountered by the boardedges 55, below permitted run rates of 120-160 fpm with littlenoticeable difference in surface finish as the run rate is increased:

TABLE A SEALING PRESSURE ELEMENT PAIR TEMPERATURE (° F.) (INTERFERENCE)1 475 0.035″ 2 465 0.035″ 3 120 0.035″ 4 120 0.035″ 5 120 0.035″

It is expected that a sturdy machine with five pairs of sealing elements100 as described in the foregoing embodiment could be run at 200 ft/minwith good sealed edges 55.

As further shown in FIGS. 7 and 8, in preferred embodiments, sealinghead elements 100 are connected to dovetail guide blocks 180 that enablethe sealing head elements 100, and respective sealing units 105, to bemoved forward and backward as a respective guide block 180 is movedwithin a corresponding guide channel of the machine frame. It will beappreciated that moving a guide block 180 and corresponding sealing headelement 100 will increase or decrease the distance between a pair ofsealing head elements 100 to provide desired friction and compressionfor achieving desired sealing results of a board 50 with a particularthickness. It will also be appreciated that one sealing head element 100of a pair could be provided with a guide block 180 for movement andestablishing the distance between a pair of sealing units 105, or eachsealing head element 100 in a pair could each be provided with acorresponding guide block 180.

In the preceding specification, various embodiments have been describedwith reference to the accompanying drawings. It will, however, beevident that various modifications and changes may be made thereto, andadditional embodiments may be implemented, without departing from thebroader scope of the exemplary embodiments as set forth in the claimsthat follow. The specification and drawings are accordingly to beregarded in an illustrative rather than restrictive sense.

What is claimed is:
 1. A system for sealing a cut edge of a polymerboard comprising: a plurality of rollers automatically advancing apolymer board including a cut edge; and a stationary, non-spinning andheated element contacting and compressing the cut edge of the board. 2.The system of claim 1, wherein the board comprises cellular polyvinylchloride.
 3. The system of claim 2, further comprising a pair ofstationary, non-spinning and heated elements contacting and compressingopposite cut edges of the board.
 4. The system of claim 3, furthercomprising multiple pairs of stationary, non-spinning and heatedelements contacting and compressing opposite cut edges of the board. 5.The system of claim 4, wherein at least one pair of heated elements ishotter than another pair of heated elements.
 6. The system of claim 1,further comprising at least one stationary corner shaping elementconfigured to contact and push a corner of the board into a more roundedshape.
 7. The system of claim 6, further comprising a plurality ofstationary corner shaping elements configured to contact and push aplurality of corners of the board into a more rounded shape.
 8. Thesystem of claim 6, wherein at least one corner shaping element is anangled rod.
 9. The system of claim 8, wherein the rod is at an angle ofabout 45 degrees to each corner.
 10. The system of claim 6, wherein atleast one corner shaping element is spool-shaped.
 11. The system ofclaim 10, wherein the spool-shaped shaping element floats up and downwithout spinning.
 12. The system of any of claim 1 wherein the board isadvanced by the rollers at run rate of from 20 to 200 ft/min.
 13. Amethod of sealing a cut edge of a polymer board comprising:automatically advancing a polymer board including a cut edge; heatingthe cut edge; and contacting and compressing the cut edge with astationary, non-spinning element to seal the cut edge.
 14. The method ofclaim 13, wherein the non-spinning element has a rounded surface. 15.The method of claim 13, further comprising contacting and compressingopposite cut edges of the board with an opposite pair of stationary,non-spinning elements to seal the opposite cut edges.
 16. The method ofclaim 15, wherein the pair of stationary, non-spinning elements areheated.
 17. The method of claim 13, further comprising contacting andpushing a corner of the board with a stationary corner shaping elementto provide a more rounded corner.
 18. The method of claim 17, whereinthe corner shaping element is an angled rod.
 19. The method of claim 17,wherein the corner shaping element is spool-shaped.
 20. The method ofclaim 19, wherein the spool-shaped corner shaping element floats up anddown without spinning.